Inkjet printed livery application process

Abstract

A method of treating a contoured surface with surface treatment layer includes applying a surface preparation layer along the contoured surface and applying a basecoat layer on top of the surface preparation layer. The method further includes stabilizing the basecoat layer to prepare a basecoat surface along the basecoat layer for one or more subsequent layers of the surface treatment coating and jetting a decorative livery layer along the contoured surface using one or more ink jet print heads. The method further includes applying an adhesion promoter on top of the decorative livery layer and stabilizing the adhesion promoter layer to produce a desired bonding surface along the adhesion promoter layer. Additionally, the method includes applying a clear coat layer to cover the underlying decorative livery layer, the basecoat layer and the surface preparation layer.

What is claimed is: 
     
       1. A method of treating a contoured outer surface with a surface treatment coating, the method comprising:
 applying a surface preparation layer along the contoured outer surface; 
 applying a basecoat layer on top of the surface preparation layer and along the contoured outer surface; 
 stabilizing the basecoat layer to prepare a basecoat surface for one or more subsequent layers of the surface treatment coating; 
 jetting a decorative livery layer along the contoured outer surface using one or more ink jet print heads; 
 applying an adhesion promoter layer on top of the decorative livery layer; 
 stabilizing the adhesion promoter layer to produce a desired bonding surface along the adhesion promoter layer; and 
 applying a clear coat layer to cover the decorative livery layer, the basecoat layer and the surface preparation layer. 
 
     
     
       2. The method of  claim 1 , wherein the surface preparation layer includes one or more of a surface film, a sol-gel layer, a primer layer, and an intermediate layer. 
     
     
       3. The method of  claim 1 , wherein stabilizing the basecoat layer includes evaporating one or more basecoat volatile materials from the basecoat layer. 
     
     
       4. The method of  claim 3 , wherein stabilizing the basecoat layer further includes curing the basecoat layer at an elevated temperature for a pre-determined time. 
     
     
       5. The method of  claim 4 , wherein the basecoat layer is cured sufficiently to promote wetting of the decorative livery layer along the contoured outer surface. 
     
     
       6. The method of  claim 1 , wherein the decorative livery layer includes a plurality of different colored inks, and wherein jetting the decorative livery layer produces a multi-colored layer having a uniform thickness. 
     
     
       7. The method of  claim 6 , wherein the multi-colored layer is formed from a plurality of ink drops dispensed by the one or more ink jet print heads and each ink drop of the plurality of ink drops has an approximate volume of at least 30 picoliters. 
     
     
       8. A method of applying a decorative livery layer along a contoured outer surface of an airplane fuselage, the method comprising:
 positioning the airplane fuselage within a work area; 
 preparing the contoured outer surface of the airplane fuselage for receiving a surface treatment coating; 
 applying a surface preparation layer along the contoured outer surface; 
 jetting a decorative livery layer along the contoured outer surface using one or more ink jet print heads; 
 applying an adhesion promoter layer on top of the decorative livery layer; 
 stabilizing the adhesion promoter layer to produce a desired bonding surface along the adhesion promoter layer; and 
 applying a clear coat layer to cover the decorative livery layer, and the surface preparation layer. 
 
     
     
       9. The method of  claim 8 , wherein preparing the contoured outer surface includes performing at least one of abrading, cleaning, washing, and drying the contoured outer surface. 
     
     
       10. The method of  claim 8 , wherein the surface preparation layer includes one or more of a surface film, a sol-gel layer, a primer layer, and an intermediate layer. 
     
     
       11. The method of  claim 8 , further comprising applying a basecoat layer on top of the surface preparation layer and wherein applying the basecoat layer includes stabilizing the basecoat layer to prepare a basecoat surface for one or more subsequent layers of the surface treatment coating. 
     
     
       12. The method of  claim 11 , wherein stabilizing the basecoat layer further includes curing the basecoat layer at an elevated temperature for a pre-determined time. 
     
     
       13. The method of  claim 12 , wherein the basecoat layer is cured sufficiently to promote wetting of the decorative livery layer along the contoured outer surface. 
     
     
       14. The method of  claim 8 , wherein the decorative livery layer includes a plurality of different colored inks, and wherein jetting the decorative livery layer produces a decorative layer with one or more colors and having a uniform thickness. 
     
     
       15. The method of  claim 14 , wherein the decorative layer with one or more colors is formed from a plurality of ink drops dispensed by the one or more ink jet print heads and each ink drop of the plurality of ink drops has an approximate volume of at least 30 picoliters. 
     
     
       16. A method of ink jetting a decorative livery layer along a contoured outer surface of an aircraft using a surface treatment assembly with one or more ink jet print heads, the method comprising:
 applying a surface preparation layer along the contoured outer surface, the surface preparation layer includes one or more of a surface film, a sol-gel layer, a primer layer, and an intermediate layer; 
 applying a basecoat layer on top of the surface preparation layer and along the contoured outer surface; 
 curing the basecoat layer sufficiently to stabilize the basecoat layer; 
 jetting a decorative livery layer along the contoured outer surface using the surface treatment assembly; 
 flashing one or more volatile components from the decorative livery layer; 
 applying an adhesion promoter layer on top of the decorative livery layer; 
 stabilizing the adhesion promoter layer to produce a desired bonding surface along the adhesion promoter layer; and 
 applying a clear coat layer to cover the decorative livery layer, the basecoat layer and the surface preparation layer. 
 
     
     
       17. The method of  claim 16 , wherein curing the basecoat layer comprises heating the basecoat layer at an elevated temperature for a pre-determined time. 
     
     
       18. The method of  claim 16 , wherein the decorative livery layer includes a plurality of different colored inks, and wherein jetting the decorative livery layer produces a multi-colored layer having a uniform thickness. 
     
     
       19. The method of  claim 18 , wherein the multi-colored layer is formed from a plurality of ink drops dispensed by the one or more ink jet print heads and each ink drop of the plurality of ink drops has an approximate volume of at least 30 picoliters. 
     
     
       20. The method of  claim 16 , wherein the basecoat layer is cured sufficiently to promote wetting of the decorative livery layer along the contoured outer surface.